Projects

B&J Catalano has a strong track record of operational partnership in a number of major projects across the state. The Company’s services and people are distinguished by excellence in operational, environmental and safety performance. B&J Catalano are unique in the way we do business. Through company ownership of a full fleet of plant and equipment, in house maintenance and long term staff, we offer reliability umatched in the industry. B&J Catalano are a one stop shop, limiting the use of subcontractors to only the most specialised tasks, giving us the control we need to provide a safe, reliable and quality service to our clients. B&J Catalano have been constructing civil infrastructure including roads and tailing dams for over 30 years. From South 32's Worsley Alumina site in the South West of WA, to MMG's Golden Grove in the Midwest, right up to FMG's Solomon in the Pilbara.

Construction from Greenfield site of a 25m high Tailings Storage Facility. The project demands productions of 20,000m3 of completed embankment daily. B&J Catalano are utilizing our fleet of scrapers to complete the project ahead of schedule and budget.

Plant and Equipment Requirements:

B&J Catalano operates a fleet of Caterpillar 657 Scrapers and 777 Dump-trucks along with numerous Caterpillar 16 Graders and compactors in order to complete the scope. Fleet repair and maintenance is undertaken on-site in our mobile workshop facility.

Load and haul various grades of ore and waste to the ROM pad and waste dump respectively - 12,000 to 15,000 tonnes per shift. Crusher feed on a 24 hour basis. Load and haul calcine from the calcine drainage vat, load and haul fines from the crusher area to the dry tailings stockpile. Miscellaneous civil maintenance work in and around the plant facility.

Plant and Equipment Requirements:

B&J Catalano operated a fleet of Caterpillar 777 dump trucks and an Hitachi EX 1200 excavator, an Hitachi 870 excavator and 50 tonne articulated trucks, a 988 loader on the ROM pad and various support equipment including graders, water carts, service trucks and track and rubber tyre dozers. B&J Catalano also crushed and haul product off site with a fleet of on road highway trucks.

The works included clearing and grubbing, topsoil removal, foundation key construction, embankment construction, drainage works and crest road construction. The contract also included the earthworks and roadworks associated with the new Pump Station and Water Treatment Plant construction contracts adjacent to the Clear Water Dam site. The Clear Water Dam contract was successfully delivered both ahead of schedule and within budget.

Construction of the Water Body 1 above ground dam adjacent to the Worsley Refinery with scope of works that includes clearing, embankment construction, liner installation, replacement and relocation of services, piping installation and associated pits, underdrainage construction, access and service roads, fencing and batter protection.

Construction from Greenfield site of a 20m high Tailings storage facility. The project demanded productions of 20,000 m3 of completed embankment daily. B&J Catalano utilised its fleet of scrapers to complete the project on time and budget.

Plant and Equipment Requirements:

B&J Catalano operated a fleet of Caterpillar 657 Scrapers, numerous Caterpillar 16 Graders and compactors in order to complete the scope. Fleet repair and maintenance was undertaken on-site in our mobile workshop facility.

Construction of just over 9km of sealed bitumen road, with four cement stabilized floodway’s totaling 1.6km of the project. The project was an upgrade to an existing gravel road requiring locally won material to be crushed and screened to create a suitable product for the pavements. The main alignment was a single coat seal 4m wide with floodways being a double coat seal at 8m wide. Cut to fill earthworks and all road construction activities were conducted under live traffic conditions creating some challenges when local events increased traffic flows. The project was extremely remote and all works had to be completed autonomously, requiring mobile offices and staff facilities to be self-contained and sufficient. Water supply was via ground water bores with 4 inch submersible pumps running 24 hours a day to keep up with requirements. Water testing was also required to ensure salinity did not affect the project outcomes.

Construction from Greenfields site of a fully HDPE lined 50Ha Tailings storage facility and subsequent Raise 1 and 2. The initial dam embankment ranged in height from 3m to 14m and the subsequent raises were 3m.

Typical annual scope involves the excavation to stockpile of 1.5-2M BCM of zone 1 and 2 clays, unsuitable materials, topsoil’s, gravels and rock. Around 30-40Ha of floor construction is undertaken each year. This required a piped groundwater drainage system, two layers of compacted clay floor and a gravel drainage layer encasing a piped residue draining system. Decant structures and decant lines also form part of the construction scope, either on new finished floor or raises to existing decant structures upon an upstream embankment lift. Upstream raised embankments and dividing walls are typically constructed each year in varying degrees. Up to 700,000m3 of material has been successfully placed conditioned and compacted by B & J Catalano in a year.